Ford 7.3L Power Stroke (1999-2003) :: Intermittent Rough Motor / Black Smoke And Low Power
Dec 30, 2015
I have an Excursion with 220k miles. I've owned the truck for 6+ years and had very few problems. I change my own oil and fuel filters, but beyond that I know next to nothing about the diesel motor. I do run a DP Tuner with the standard 80 hp program. And a 4" exhaust. Everything else is stock. I do keep it plugged it for the oil heater and the battery tender just about all the time now.
This latest issue started yesterday morning when my wife jumped in a cool truck to take the kids to the dentist (not warmed up but still 55 degrees ambient). A few miles down the road (35 mph max) the motor began stumbling and rocking and black smoke coming from the exhaust with reduced power. She pulled off and kept it running (very rough and rocking) and put it in park for a minute. When she put back in drive, it shifted heavily but the power was normal so she went on her way without any problems. The only report I got sounded like the motor was just cold and rough, so I thought nothing more of it.
Yesterday evening we drove it about 70 miles on the highway (72 mph max) with no issue at all, but when we continued on surface streets toward our destination (50 mph max) it did the same thing, but would not settle back down. I kid you not that it went through gallons of fuel the last 12 miles or so, just dumping black smoke out the exhaust. It felt to me like we were running 1/2 the motor, like the plugs weren't lit. Very rough and rocking and very little power (comparatively, at least). I had to switch to manually shifting the trans to get going and the shifts were much rougher than usual. Idle was low and rough but it never stalled. Behind me there was a huge smoke screen this entire time.
We made it to our destination and parked it. Did our thing and after 5 hours went out with finger crossed. Started right up and ran perfectly the entire 91 miles home. No motor or trans issues at all. Currently running 10/40 synthetic oil that I just changed about 2000 miles ago. Oil level is perfect. 3/4 tank of fuel with standard level of Diesel Kleen added. Fuel filter is less than 10k miles old. Temps yesterday were 65-70 on the drive down and 50-55 on the way back.
I jiggled all sorts of connectors this morning and didn't find anything loose.
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Short version is that I just did the EBPV delete with new pedestal and turbo exhaust outlet and put a new turbo middle cartridge in as mine had blown a seal and possibly broken the shaft. Once I got it all put together, I took it for a test drive and it was building 20PSI like it used to but I didn't have the accumulator and turbo mated up fully so I had a leak there.
I corrected that and now don't get any boost until I get to about 2500RPM and then it only builds to about 10PSI. I've double and triple checked all my connections, boots, etc. and everything is tight on the intake, intercooler, up-pipes and collector, exhaust and the spider, I can't see or feel any problems there. I tried disconnecting the MAP sensor and it might be a little better but not even close to normal.
Tried disconnecting the red line from the wastegate and plugging it with no difference. I'm stuck, and frustrated. I do have AE, watching the MGP looks like the MAP sensor is working. I feel like I'm overlooking something simple but I just can't figure out what it is...
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On Tuesday morning I was watching an auction on my computer and saw a 2003 Ford F350 Super Duty Crew Cab Fx4 with 200K on it. It had an inspection report which is *supposed* to note every cosmetic and mechanical issue. It had nothing listed wrong with it for mechanical. I "won" and for my prize I get a rough-running 6.0 diesel delivered.
I just got off the phone with the transporter who picked it up today and he said there are no check engine lights but it is running rough with no power. So I am having him drop it off at a diesel repair shop.
Hopefully it is just something with the wiring harness but I have a feeling it's got at least a few bad injectors so I am probably screwed.
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05 6.0 deleted and studded. 170k fresh filters and oil, no CEL or codes.
This has happened 3x in months, so it intermittent. Truck will start fine cold, except for this last episode ....
Truck starts right up, idles correctly, speed bumps up if its cold enough to trigger the high idle. About mid way through its warm up, at approx 130-140 idle falls off, barely runs. Almost knocking. Black smoke if you give it throttle. Has no power when its doing this. Truck will not move and almost dies in gear. Give it til 185ish degrees then pooof! All good.
However 2 days ago it wouldn't start. Cranks but won't catch. Stumbles and dies. Finally got it to start after setting the charger on it. I killed it. But this time when it started it was straight into its rough idle, no power...until about 180. I switched it off, restarted it and it was totally fine
Ficm is 47-47.5. Every now and then I see a 46.5 for a split sec
Hpop is 700-800cold cranking.
Not sure what else to look at.
Moto craft filters.
Amsoil 5w-40
Archoil in the fuel and oil
Twc3 at every fill up.
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Normally I run around sea level at home but Iam on road trip in Wyoming at over 5000' elevation I am noticing alot more black smoke when towing. I run a DP tuner with 40 and 60hp tow mode. I also notice alot more black smoke in 60HP Econo Mode when not towing? Would this be typical due to the higher elevation?
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Bought the x in feb, put in the billeted wheel, modified the turbo pedestal, put in dorman uppies, put my boost leak detector on it and had no leaks then. Also put on the walker btm and gauges at that point. Took my chip to a local to get tunes. I was pleased enough with the power, and can hit 24 psi. However, it smokes like a freight train if I give it much pedal. I don't drive it a ton, but in the last week I did a 400 mile trip to pick up a trailer, then 800 miles on vacation in Colorado. The fender flare by the exhaust is now black.
It has to be pulling a trailer or going up a decent hill while cruising at 70 to show any boost at all on the gauge. If I give it gas, it belches out the smoke, unless I get on it and get the boost to 10 or more. Most of the time while cruising along I don't need to speed up that much so it just smokes and doesn't build more than 2 psi boost.
My f350 by comparison usually runs 4-6 psi boost running down the road at 65, and slight movements of the accelerator can affect that number immediately.
I don't have my leak detector with me so I can't verify that I have no leaks right now, but I can still hit 24 psi... Last night I used oven cleaner and got the whole area around the turbo pretty clean. Drove it 60 miles today, and don't see any soot around anything, maybe it's to soon to tell? Is there anything else I should check, or is it as simple as getting new tunes?
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So I've been having issues with starting my truck lately. It was really hard to turn over, would start really hard when it did and would blow some black smoke. Turns out my starter was bad so I replaced it with a DB Electric high torque starter. Now it starts up great... for the most part.
I'm still having some black smoke when it's a cold start and/or I have the key set to "On" to warm the glow plugs for a few seconds. It's almost like the starter is turning over the engine, but for the first few turns it sounds empty or hollow (at least that's the best way I can describe it). After the first turns it will sound normal how it's supposed to and will fire up shortly after but with some black smoke.
If my car is already warm it cranks right up without any smoke unless I have the key set to "On" for a few seconds to warm the glow plugs like I said earlier. Pretty much if I warm the glow plugs it makes it harder to start up for some odd reason.
What might cause this or how to fix it? Maybe some of my glow plugs are going bad, or possibly my IDM? I used to have the P1670 code by itself, however, that went away when I replaced the starter. I also just replaced my camshaft position sensor just to be sure it wasn't going bad. I've also been having some boost pressure leaks if that's relevant at all.
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I have had a problem where truck would start jerking and sputtering in a certain town at low speeds. Today it happened in a new place. Barely got it to start back up. Was running rough after the puff of black smoke. Its stranded at a gas station. Recently replaced my sending unit. Was running good. Clean gas tank. Fuel lines tight. Where should I begin? I have an ICP sensor in the glove box. Truck wouldn't start.
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I have a 2003 F250CC 7.3 with 200,000 miles on it. I just purchased this truck about a month ago. My question is it blows black smoke. A little at idle but mostly when you give it any pedal. I have replaced all of the injector o rings and that didn't make a difference. Then I had it tested and it failed a CCT test on #2 cylinder. I have an injector to put in it, but am curious to find out if 1 bad injector would be enough to make it smoke all the time. I keep getting P1211 ICP pressure above desired. I had a friend of mine who used to work at a ford garage take a look at it with his computer and he said that everything looks good other than the CCT test.
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I have always seen other trucks blow black smoke with towing up a hill but mine for the most part has not. I pulled my 5er to CO this summer and notice my truck starting to blow black smoke. I consider myself a very conservative driver. I always stay around 65 MPH while towing and never push my truck up the hills. I always try to keep the RPM around 2000 and let the MPH fall where they may until I reach the summit. With the black smoke I'm starting to see what is my truck trying to tell me? It's not bad but would like to fix now before it becomes something more.
2001 F250, 4X4 crew cab, 7.3 with 205,000 miles.....
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I have a 2003 Superduty with 193k miles that is bone stock. I sold the truck to a friend and when he decided to not pay the remaining balance on the truck, I took back ownership. The truck was having heating issues and it set at a mechanic shop for nearly 2 years waiting for a diagnosis on the heating issue. Fast forward to the present and I now have the truck at my home. Heating issue was the radiator but this is no longer a concern. When I went to pick up the truck from the mechanic, the truck started fine. Every other day for the last 4-5 weeks I would start the truck with no problems.
I get the truck tagged and start driving it on a daily basis. I've put several hundred miles on it but the more I drive it, the less it wants to start. Now it's to a point where it only cranks but won't start. I can take a gas rag and hold it in the intake and eventually it will start. Once it's running, it runs great and has no issues starting. But once it sets for 3-4 hours, it won't start without some sort of assistance.
While trying to find the issue, I've found and repaired 2 fuel leaks and in the process I replaced fuel filter, air filter, replaced glow plug relay, replaced batteries, replaced CPS. Fuel pump is working fine. I've tried the ICP test and doesn't make a difference.
The glow plug light or WTS light works so don't think its the GP. The CES light was on. Had it scanned and it was the air bag sensor so no support from the CES.
While I was working on it yesterday and after cranking on it for 5-10 minutes, it would act like it was going to start and black smoke would be coming out from the exhaust. I let it set to cool the starter it fired up like it had no issues.
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Was hauling a bobcat this AM and noticed something odd in my rear view. Under steady accelleration (either light or heavy foot pedal pressure - steady either way), the exhaust would puff out sporadic extreme dark clouds of smoke. The puffs weren't fast like every cylinder rotation.. but every second or so.. puff of very thick black smoke mixed in with the expected black smoke we see.
Truck has 350k miles with regular oil changes. Year ago someone hooked the injectors up to the computer software (buzz test) and all of them checked out to be in very good condition.
The same tech pointed out some dark blowby at the uppipe on the back of the engine. Other than that the truck is in pretty good condition for its age. What could the sporadic very thick/dark puffs of black smoke indicate?
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I have a 2003 with 150k miles. My 6.0 has black smoke and can barely crawl up a hill. Dealership is 30 days out for an appt. Air filter, oil change, alternator, and batteries are new. I removed the EGR valve and cleaned, but the valve seat is not perfect. I can see 20 to 30 mil gap around half of the seat. Is this ok or will that little gap cause this?
Hoses all look good. No alarm lights. I have no diagnostic tool but I can use a meter well. It did have an airbag light but I found the fuse missing and replaced it. The air filter alarm switch fell apart but I bypassed it till I get new part. No alarm lights now.
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Ok I'm working on a 2000 7.3 on a F550 truck was running but had no power so we changed out all the injectors and glow plugs and rebuilt the turbo now there is no start it turns over and were getting black smoke from the tail pipe. What is going on with it?
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Truck started running rough on way home the other day. First gave me P0404 code and would get black smoke along with whitish smoke coming from the tail pipe. I haven't been able to notice or track an amount of coolant loss yet.
Swapped EGR valve this morning and now noticed this once she kicked into high idle (still warming up). About to hook up the IDS, hoping I this is not head gasket .
[URL] .....
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For the last couple months I've been messing with a P1118 code. Started a few months ago when I noticed my fuel mileage was down 1-2MPG. Also sometimes a rough seeming idle (hard to tell with the diesel). Then it threw a P1118, so I replaced the temp sensor under the turbo. The code went away for a while then came back, fuel mileage didn't change. So I replaced the temp sensor in the air filter box.
The code went away AND my fuel mileage seems to have come back to normal. Now, code thrown again. Search on P1118 hasn't been super useful. Seems like replacing the sensor under the turbo is the trick. Also seems to come up in combination with a bunch of other codes with battery problems. I suppose it's possible I have some sort of electrical gremlin. It throws the code on startup and stays on until I shut it off. Doesn't come on every time, is off more often than on.
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My truck is an 03 and I changed number 5 injector and number 4 injector, checked my ficm everything is good there now I have a contribution balance code for injector 4 now injector 5 and an EGR code some guys on hear before said it could be a sensor but today I talked to my mail man who also owns a 6.0 and he sounds pretty knowledgeable he says it's possible that it could be that the computer is not reading out right and those cylinders are getting to much fuel for an instant that's what's causing the sudden puffs of black smoke. My torque pro is giving me all these codes and I'm starting to think that there is something underlying....
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I had been fighting some problems with injectors for several years. I didn't have time to dig into it. I knew what I needed to do, just needed to find time to do it. I honestly thought it was and injector and thought I would have to go to new sticks because I've had so many problems with the remans.
Well I finally had time last week. I pulled the passenger side valve cover and ohmed the injectors. It would be almost impossible to get the leads in the injector while installed the truck. I kept an old valve cover harness, so I cut a pig tail off of it and plugged it into the injectors so I could test. You can see the meter attached to the pigtail in the pic.
To my surprise all four were all right around 2.7 ohms. You need to set your meter so you are getting a reading w a decimal. If you set it to high it will only show a whole number and it is better to have a more accurate reading.
I then plugged the wiring harness back in and tested it from there. The #7 injector gave over 6 ohms. This told me that my wiring harness was bad. I went OE and replaced it. I had a problem w a Dormant valve cover gasket before so didn't want to go that route. After I replaced the gasket and harness all my readings were under 3 ohms. They were all lower than w the old harness.
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I have a 2001 7.3 that almost has everything practically brand new... new hpop, water pump, uvch, gpr, glow plugs, icp sensor, ipr sensor, cps and new turbo pedestal that was leaking oil, well now my truck has a cold start to where it has to be plugged in to start and when it finally does it smokes white pretty bad, misses and sounds like it's jumping around under the hood up until it warms up and revs fine with less white smoke but still a miss!!
Compression on test has been done, and good, fuel pressure is good, but the buzz test when cold shows 123457 muffled and quite and when the truck is warm only 3 and 4 are still muffled and quite? Injectors sticking?? Or just need New injectors!
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I have a 2003 Ford Excursion with the 6.0 diesel. Just driving the truck today and it was putting out black smoke. What could be causing it? No tuner on my truck, just a 4 inch straight pipe and a k&n air intake (bullet proofed, but thats not for performance) ....
2003 ford excursion 6.9, black smoke, why? - YouTube ....
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I have a 03 6.0. I just had all the injectors changed a new fuel pump, spring in the regulator and fuel filters ouch. The truck runs great but I get a puff of black smoke if I get on the throttle going down the road it seem to clear up as soon as the turbo spools up. I that ok or do I need to take it back to the dealer?
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